GIFT  OF 


ENGINEERING    LIBRARY 
OF 

WILLIAM   B.  STOREY 

A  GRADUATE  OF 

THE    COLLEGE    OF    MECHANICS 
CLASS   OF  1881 

PRESENTED  TO  THE  UNIVERSITY 
1922 


EUBCTRIC 
WELDING 


CATALOGUE 
NUMBER  ONE 


THE  WILSON  WELDER 
#  METALS  COM PANYlNc. 

N  EW  YORK  CITY,  U.S.A. 


OFFICERS  & 
DIRECTORS 


OFFICERS 
S.  A.   MEGEATH 

President 

W.  E.  SYMONS 

Assistant  to  President 

D.   H.  WILSON,  Jr. 

Vice-President 

L.  G.  SHORTHOUSE 

Secretary  and  Treasurer 


DIRECTORS 

GENERAL  CHARLES  MILLER 

S.  A.  MEGEATH 
D.  H.  WILSON,  Jr. 


WHY  THIS  BOOK 
IS    PUBLISHED 


HEN  it  was  proposed  to  cross  the  Atlantic  Ocean  with 
a  ship  propelled  by  steam,  the  greatest  English  engineer 
and  scientist  at  that  time  ridiculed  the  idea  and  said 
it  would  be  quite  as  feasible  to  make  a  trip  to  the  moon  (distance 
238,840  miles),  while  men  of  prominence  in  the  engineering  pro- 
fession, both  in  England  and  America,  looked  upon  the  early  efforts 
of  our  pioneer  marine  engineers,  Robert  Fulton  and  John  Fitch, 
as  being  the  product  of  unsound  minds. 

For  ages  it  was  thought  welding  could  only  be  accomplished 
by  the  traditional  Blacksmith.,  with  Forge,  Anvil  and  Hammer. 
But  in  this,  as  in  many  other  of  the  arts  and  sciences,  there  has 
been  great  strides  in  recent  years. 

Electricity  is  now  doing  for  man  what  steam  has  done  in 
the  past  eighty  or  one  hundred  years. 

The  railways  spent  last  year  for  maintenance  of  way  and 
equipment  the 

STUPENDOUS  SUM  OF $951,416,485.00 

Just  how  much  of  this  could  have  been  saved  by  the  use  of  a 
first-class  ^Electric  Welding  System  we  do  not  know.  We  do  know, 
however,  that  the  saving  in  One  Year  will  more  than  pay  for  an 
equipment  in  service. 

In  the  following  pages  may  be  found  details  of  an  Electric 
Welding  System  and  Specially  Prepared  Metals,  together  with 
examples  of  possible  economies  from  its  use,  that  should  be  of 
interest  alike  to  the  Workman,  Official  or  Shareholder. 


Why  this  Book  is  Published 5 

Development  of  Wilson  System 7 

Superiority  of  Equipment  and  Metals    .    . 8-9 

Half-tone  Cuts,  Blue-prints  and  Charts 10-20 

Specifications  of  Equipment ,    .  21-30 

Portable  Equipments 31-38 

Size,  Weight  and  Use  of  Electrodes  and  Schedule  of 

Equipment 35-36 

Floor  Plans  and  Weights 39-40 

Table  of  Economies  and  Half-tone  Cuts  of  Repairs  Made  41-46 

Physical  Tests  of  Welded  Plate 47-49 

Economy  in  Operation      50 

A  Lesson  in  Preparedness 51 

Useful  Information,  Wiring  Formula,  Tables,  etc.    .    .    .  52-58 

How  We  Have  Been  Received 59 

Statistical  Blank  Forms 60-61 

General  Index                                                                         .  62-63 


PRESENTED  TO 


WITH   COMPLIMENTS  OF 


Wilson  Welder  and  Metals  Company 

Incorporated 

DEVELOPMENT   OF  THIS   SYSTEM 

THE  Wilson  System  of  Electric  Welding  was  developed  on  a 
large  trunk  line  railroad.  Some  years  ago  this  road  was 
among  the  first  to  introduce  electric  welding,  which  proved 
to  be  very  economical,  especially  when  making  quick  repairs.  Its 
adoption,  however,  soon  developed  the  fact  that  while  the  most  ex- 
pert operators  secured  fairly  good  results  on  some  classes  of  work  this 
was  the  exception  rather  than  the  rule.  Consequently  there  were 
many  failures,  due  to  defective  welds,  that  bore  evidence  of  dam- 
age from  excessive  heat.  As  these  conditions  became  more  serious 
the  railroad  officers,  after  satisfying  themselves  that  the  heat  could 
not  be  properly  controlled  by  any  of  the  electric  welding  systems  on 
the  market  at  that  time,  resolved  to  develop  a  Welding  System 
that  would  control  the  heat,  and  eliminate  the  personal  equation 
as  much  as  possible. 

After  consulting  various  electrical  engineers  regarding  the 
design  and  construction  of  a  machine  that  would  control  the  heat 
of  the  arc,  with  little  or  no  encouragement,  the  problem  was 
assigned  to  the  Railway  Company's  Chief  Electrical  Engineer  to 
work  out. 

After  a  long  period  of  scientific  research  and  experimental 
work  a  machine  was  produced  that  could  be  regulated  at  any  pre- 
determined heat  and  hold  that  heat  constant  (within  approximately 
6%)  as  long  as  the  arc  was  maintained.  In  comparison  with  other 
machines  then  in  use  on  the  line,  it  was  found  that  welds  made 
under  the  same  identical  conditions  by  this  machine  showed  far 
greater  tensile  strength  and  ductility.  This  System  was  then  given 
more  than  one  year's  test  on  all  kinds  of  railway  maintenance  work, 
after  which  able  critics  endorsed  it  as  the  most  advanced  state  of 
the  art,  both  as  to  Economy  in  Operation  and  High  Character  oj 
Product. 


The  Wilson  System 

ITS  SCOPE  OF  WORK  AND   POINTS    OF    SUPERIORITY 

THE  Wilson  System,  of  Electric  Welding  is  the  latest  and  most 
scientific  system  now  on  the  market.    Machinery  from  small 
details  to  massive  parts   is  readily  repaired  at  small  cost. 
Cast  steel,  cast  iron,  wrought  iron,  brass,  copper,  and  in 'fact  any 
weldable  metal,  can  be  welded  with  this  System. 

In  comparison  with  other  systems  on  the  market  the  Wilson 
System  uses  from  33  to  50%  of  the  power  required  for  the  same 
operation.  Also,  a  very  material  saving  in  labor  is  effected,  due  to 
the  fact  that  the  control  of  the  energy  is  placed  conveniently  for  the 
operator,  which  eliminates  the  necessity  of  having  to  go  back 
and  forth  between  the  work  and  control  board. 

This  is  the  only  device  which  enables  any  number  of  welders 
to  work  from  one  large  machine  without  one  welder  interfering 
with  the  work  of  another.  The  power  is  located  at  one  point,  where 
it  can  have  proper  supervision,  and  it  can  be  distributed  to  con- 
venient points  throughout  the  shop,  which  is  preferable  to  having 
a  number  of  individual  motor  sets,  with  the  consequent  greater 
cost  of  operation  and  maintenance. 

Attention  is  drawn  to  the  fact  that  welding  with  the  Wilson 
System  is  uniform.  This  superiority  over  other  systems  is  due 
to  the  fact  that  the  heat  is  controlled  at  the  point  of  application 
of  the  metal.  In  welding  there  is  a  critical  temperature  at  which 
steel  can  be  worked  to  give  the  greatest  tensile  strength,  and  also 
ductility  of  metal.  By  raising  the  heat  15  or  20  amperes  above  this 
critical  amperage  a  fracture  of  the  weld  will  show  segregation  of 
carbon  and  slag  pockets,  which,  of  course,  weakens  the  weld.  If 
the  amperage  is  decreased  from  the  critical  temperature,  a  fracture 
of  the  weld  will  show  that  the  metal  has  been  deposited  in 
globules,  with  many  voids,  which  proves  that  the  weld  has  been 
made  with  insufficient  heat.  This  shows  that  with  a  fluctuating 
amperage  or  voltage,  it  is  impossible  to  obtain  the  uniformly  high 
grade  welds  made  by  the  Wilson  System. 

From  the  foregoing  may  be  formed  a  general  idea  as  to  the 
efficiency  of  the  Wilson  System  as  applied  to  restoring  broken 
and  damaged  parts  of  all  kinds  of  Machinery  and  Boilers  without 
regard  to  their  form,  weight,  original  condition  or  use — a  field, 
by  the  way,  differing  widely  from  its  value  in  Manufacturing  Lines. 


Specially  Prepared  Welding  Metals 

IN  the    earlier    application  of  Electric  Welding,  attention  was 
directed  solely  to  developing  the  machines  employed  in  the  op- 
eration, and  very  little  to  the  welding  metal  used,  or  how  it 
should  be  used,  with  the  result  that  many  welds  failed,  due  to  the 
change  in  characteristics  of  the  metal  resulting  from  the  effect  of 
heat  from  the  electric  arc. 

The  Wilson  System  of  Welding  not  only  controls  fluctuations 
of  the  heat  at  the  arc,  but  also  provides  metals  that  are  not  adversely 
affected  by  the  heat  of  the  arc.  Our  specially  prepared  welding 
metal  is  in  the  form  of  an  electrode  and  is  composed  of  a  homo- 
geneous alloy  combined  with  such  excess  of  manganese  as  will 
compensate  for  losses  while  passing  through  the  electric  arc,  thus 
insuring  a  substantial  amount  of  manganese  in  the  welded  joint 
which  is  essential  to  its  toughness. 

We  also  have  a  manganese  copper  alloy  welding  metal  electrode 
which  is  composed  of  iron  homogeneously  combined  with  such  an 
excess  of  manganese  and  copper  over  the  amount  lost  in  the  arc  as 
will  insure  to  the  welded  joint  a  substantially  additional  degree  of 
toughness  and  ductility.  WTith  no  other  system  of  welding  can 
these  metals  be  used.  Therefore,  such  merit  as  they  possess  is  only 
available  to  those  who  use  our  equipment  and  metals,  whose  interest 
in  the  advanced  state  of  the  art  we  stand  committed  to  serve.  We 
have  developed  each  of  these  metals  to  the  highest  point  of  effi- 
ciency through  the  services  of  some  of  the  best  metallurgists  in  the 
United  States,  and  to  insure  their  proper  composition  and  uni- 
formity, the  mills  maintain  complete  records  and  analysis  of  each 
heat. 

These  metals  are  patented  for  the  joint  protection  of  our 
customers  and  ourselves.  For  details  see  page  35. 


Welding  Tool  or  Electrode  Holder  with  Distant  Control  Switch 


Direct  Current 

Starter 

No-Voltage 

Release 


Polyphase 
Starter 

No -Voltage 
Release 


10 


PHOTOGRAPHS  OF  EQUIPMENT 

AND 

SPECIFICATIONS 

OF 

DESIGN,  CONSTRUCTION 
AND  MATERIAL 

WILL  BE  FOUND  IN  PAGES  10  TO  40 
INCLUSIVE 


11 


Four  Arc,  or  600  Ampere  Capacity,  Motor-Generator  Set  Alternating  Current 


Four  Arc,  or  600  Ampere  Capacity,  Motor-Generator  Set  Direct  Current 


13 


14 


WIRING     DIAGRAM    FOR    WIL-SON    WELDING     PANEL 


Plug  Fuse 


• 


Post  five  L/r>e 


S^x  IK  o>f 


WELDING     TOOL    AND    COMTftOL   Ct/fCU/T. 

WILSON  WELDING  AND  METALS  CO.,  INC. 

SS      VANDERBILT    AVENUE 
NEW    YORK     CITV    . 


ff£TffACED     3- 14-16. 


PRINT     No. 


Wiring  Diagram  of  Wilson  Welding  Panel  Control  Switch, 
and  Electrode  Holder 


15 


3. 


4. 


Wilson  Welder  and  Metals  Company 

Incorporated 

52  Vanderbilt  Avenue,  New  York  City 


CATALOGUE  OF  PARTS 

OF 

WELDING   GENERATORS   AND   MOTORS 


GENERAL  DIRECTIONS  FOR  ORDERING  REPAIR  PARTS 

Always  give  the  machine  number  as  stamped  on  the  name  plate 

and  state  whether  the  machine  is  a  generator  or  a  motor. 

Give  both  name  and  number  of  part  wanted. 

Shunt  Field  Coils  and  Series  Field  Coils  are  shipped  fully  insulated 

and  ready  for  assembly  in  machine. 

Armature  coils  for  both  motor  and  generator  of  1,  2  and  4-arc  sets 

are  shipped  fully  insulated.     For  6  and  8-arc  sets,   separate  slot 

boxes  are  used  and  should  be  separately  ordered. 

DIRECT  CURRENT  MOTORS  AND  GENERATORS 
List  of  Parts  by  Number  and  Name 


1 

2 

3 
4 
5 
6 
7 
8 
9 

10 
11 
12 
13 
14 
15 
16 
17 

18 

19 

20 


101 
102 
103 
104 


Field  Ring.  22 

Bearing  Bracket.  23 

Bearing  Bracket  Bolt.  24 
Winding  Guard. 

Winding  Guard  Bolt.  25 
Bearing  Bushing. 

Oil  Ring.  26 

Oil  Hole  Cover.  27 

Oil  Gauge.  28 

Commutation  Pole.  29 

Commutation  Pole  Bolt.  30 

Pole  Piece.  31 

Pole  Piece  Bolt.  32 

Shunt  Field  Coil.  33 

Series  Field  Coil.  34 

Commutation  Pole  Coil.  35 
Commutation  Pole  Insulating     36 

Washers.  37 
Commutation   Pole   Core   In-     38 

sulation.  39 

Brush.  40 
Brush  Yoke. 

Brush  Yoke  Set  Screw.  41 


Brush  Holder. 
Brush  Holder  Spring. 
Brush   Holder   Insulating 
Washer. 

Brush   Holder   Insulating 
Bushing. 
Commutator. 
Commutator  "V"  Ring. 
Commutator  Shell,  Back  Part. 
Commutator  Shell,  Front  Part. 
Commutator  Shell  Nut. 
Armature  Coil. 
Armature  Core. 
Armature  Clamping  Plate. 
Armature  Shaft. 
Ventilating  Fan. 
Base. 

Holding  Down  Bolts. 
Terminal  Block. 
Armature  Binding  Wire. 
Commutator    Cross     Connec- 
tions. 
Armature  Slot  Boxes. 


INDUCTION    MOTORS 

Stator  Frame  and  Core.  105     Rotor  Bar. 

Stator  Coil.  106     Rotor  End  Ring. 

Stator  Slot  Wedge.  107 

Rotor  Core.  108 


Rotor  Shaft  Key. 
Stator  Slot  Box. 


16 


fower-  f0c?~o/~   cvise  ss  Sbr  j/?t/vc/?o/? 
Vo/foye   /s    co/jsr0s??~  of   35  VO//TS  S 


100       zoo       300      400      sco      600      700       goo      900      /ooo      //oo 


SPECIFICATIONS   FOR 

Electric  Arc  Welding  Motor-Generator  Sets 


CONSISTING  OF 


Direct  Current,  Compound,  Interpole  Generators  and 
Squirrel  Cage,  Polyphase,  Induction  Motors 


GENERAL — The  machines  are  designed  and  built  with  special 
reference  to  the  intermittent  character  of  the  load  to  be  carried  and  will 
be  so  adjusted  as  to  operate  with  fixed  brushes  at  any  load  from  no-load 
to  maximum,  and  will  not  show  any  tendency  to  flash  when  maximum 
is  suddenly  removed. 

The  entire  magnetic  circuit  of  the  generator  is  constructed  of  thin 
sheet  steel  plates,  castings  being  used  only  for  mechanical  and  not  for 
magnetic  purposes,  thus  providing  an  extremely  quick  recovery  coefficient 
and  permitting  the  operation  of  more  than  one  welding  circuit  from 
the  generator  without  interference. 

The  commutation  will  be  sparkless  under  all  conditions  and  changes 
of  load  within  the  rating  of  the  machine  arid  the  set  will  operate  without 
undue  noise  or  vibration. 

DATA 

Rated  Capacity  of  Generator 


in  Welding  Arcs      

1 

2 

4 

6 

8 

Rated   Capacity  of  Generator 

in  Amperes  

150 

300 

600 

900 

1200 

Rated   Capacity   of   Motor  in 

Horse  Power    *   . 

iy> 

15 

30 

45 

60 

Full  Load  Speed     ... 

'  /  £i 

1750 

1150 

1150 

1150 

1150 

Number  of  Poles  on  Motor  .    . 

4 

6 

6 

6 

6 

Number  of  Poles  on  Generator* 

4 

4 

4 

4 

4 

Number  of  Interpoles    .... 

4 

4 

4 

4 

4 

Voltage  of  Motor    

220  or  440 

220  or  440 

220  or  440 

220  or  440 

220  or  440 

Voltage  of  Generator     .... 

35 

35 

35 

35 

35 

Temperature  Rise  —  Duty  Cycle 

50°C 

50°C 

50°C 

50°C 

50°C 

Overall  Efficiencies  at 

Full  Load 

%  Load 

y^  Load 

%  Load 

Power  Factor  at  Full  Load  .    . 

Length  of  Set  in  Inches     .    .    . 

"42% 

57y2 

66^ 

74% 

82% 

Width  of  Set  in  Inches  .... 

14 

18% 

21% 

28 

28 

Weight  of  Set  in  Pounds  .    .    . 

1000 

1600 

2200 

4100 

4300 

ELECTRIC   WELDING  MOTOR-GENERATOR  SET 

CONSTRUCTION — This  Motor-Generator  Set  will  consist  of  a  Squirrel 
Cage  Induction  Motor  and  35-Volt,  Direct  Current,  Compound  Wound, 
Interpole  Generator,  mounted  on  a  heavy  cast  iron  subbase  and  provided 
with  self-oiling  bearings  lined  with  hard  genuine  babbitt. 

The  rotors  of  both  machines  being  mounted  on  a  single  shaft  of 
high  carbon  steel  supported  on  two,  three  or  four  bearings,  the  bearing 
housing  of  the  set  will  be  of  the  demountable  type  so  as  to  permit  the 
easy  removal  of  the  rotors. 

Compensators  equipped  with  a  No- Voltage  release  will  be  furnished 
with  each  set. 

Machines  will  be  of  the  protected  type  and  in  strict  accordance 
with  the  Standardization  Rules  of  the  A  I  E  E — Class  "A"  insulation 
being  used  throughout,  with  the  exception  of  the  commutator,  which 
will  be  mica  insulated. 

INDUCTION   MOTOR 

STATOB — The  stator  core  will  be  built  of  punchings  of  thin  sheet 
steel  of  high  magnetic  quality,  each  sheet  being  varnished  to  reduce  the 
core  losses.  The  core  will  be  rigidly  held  and  supported  by  two  heavy 
cast  iron  clamping  rings  which  form  the  frame  of  the  stator — all  bolts 
holding  these  clamping  rings  together  being  outside  of  the  magnetic 
circuit. 

The  windings  will  be  of  form  wound  coils,  treated  with  insulating 
compound,  taped,  varnished  and  baked.  The  slots  of  the  winding  of 
the  Six  and  Eight  Arc  Machines  will  be  lined  with  insulating  material 
of  the  best  quality  suitable  for  the  purpose — form  pressed  coils  being 
used  in  the  smaller  size  machines.  The  windings  will  be  securely  held 
in  place  by  wedges  driven  in  between  the  tips  of  the  core  teeth  and  the 
terminals  of  the  winding  will  be  brought  out  so  that  connection  to  the 
power  lines  may  be  easily  made,  connectors  being  supplied  for  this 
purpose. 

Neat  and  substantial  guards  will  be  bolted  to  the  frame  to  protect 
both  ends  of  the  windings  from  mechanical  injury. 

ROTOR — The  rotor  core  will  be  built  of  punchings  of  thin  sheet 
steel  of  high  magnetic  quality,  each  sheet  being  varnished  to  reduce 
core  losses.  The  core  will  be  securely  keyed  direct  to  the  shaft  between 
clamp  plates  to  prevent  the  bending  of  the  end  sheets. 


The  rotor  conductors  will  be  placed  in  partly  closed  insulated  slots, 
and  securely  riveted  and  soldered  at  both  ends  to  short-circuiting  rings. 

VENTILATION — The  periphery  of  the  stator  will  be  entirely  exposed 
to  the  air  and  where  necessary  ducts  will  be  provided  in  both  the  rotor 
and  stator  cores,  permitting  the  most  perfect  ventilation  through  cores 
and  windings. 

DIRECT   CURRENT   GENERATOR 

FIELD — The  field  will  be  of  the  ring  type,  constructed  of  laminated 
steel — no  castings  being  included  in  the  magnetic  circuit.  The  pole 
pieces,  also  built  of  laminated  steel,  will  be  belted  in  place  and  will  be 
so  arranged  that  any  field  coil  and  its  core  may  be  easily  removed.  The 
field  coils  will  be  form  wound,  without  metal  spools,  and  thoroughly 
insulated. 

Interpoles — one  for  each  main  pole  on  the  machine — will  be  used 
for  the  purpose  of  securing  improved  commutation  and  fixed  brushes. 

ARMATURE — The  armature  will  be  of  the  slotted  drum  type,  having 
a  core  of  thin  sheet  steel  of  high  magnetic  quality — each  sheet  being 
varnished  to  reduce  core  losses.  The  winding  will  be  of  formed  coils  or 
rectangular  bars,  thoroughly  insulated  and  securely  held  in  place  by 
wedges  driven  into  grooves  between  the  tips  of  the  teeth,  or  by  mica 
insulated  band  wires,  and  when  necessary  by  binding  wire  over  the  outer 
ends  of  the  coils. 

The  commutator  will  be  built  of  hard  drawn  copper  bars,  thoroughly 
insulated  with  mica  and  rigidly  held  in  place  by  heavy  clamping  rings. 

BRUSH  HOLDER — The  brush  holders  will  be  of  radial  type,  fitted 
with  carbon  brushes.  These  holders  have  no  sliding  contacts  which 
carry  current  and  the  brushes  are  easily  removable  from  the  machine. 

VENTILATION — Care  will  be  taken  to  provide  ample  ventilation  and 
where  necessary,  air  ducts  will  be  left  in  the  cores  so  that  free  circulation 
through  the  cores  and  windings  is  obtained.  A  fan  will  also  be  mounted 
integral  with  the  armature,  providing  axial  ventilation. 

WORKMANSHIP  AND   MATERIAL 

The  Wilson  Welder  and  Metals  Company,  Inc.,  guarantees  that  all 
material  and  workmanship  employed  under  this  specification  shall  be 
strictly  first  class  of  their  respective  kinds  and  for  the  purposes  used. 


GUARANTEE 

The  Wilson  Welder  and  Metals  Company,  Inc.,  guarantees  that 
Motor-Generator  Sets  built  under  this  specification  shall  be  strictly 
first  class  in  every  respect  both  mechanically  and  electrically,  and  if 
after  installation  any  part  of  the  machine  discloses  weakness  or  un- 
suitability  for  the  work  for  which  it  is  intended  on  account  of  defective 
design,  material  or  workmanship,  then,  and  in  that  event  the  Wilson 
Welder  and  Metals  Company,  Inc., will  make  this  good  without  expense  to 
the  purchaser  any  time  inside  of  one  year  from  date  of  installation  and 
trial  test,  provided  the  entire  equipment  is  operated  in  accordance  with 
our  instructions  and  advice. 


Signed. 

Wilson  Welder  and  Metals  Company,  Inc. 


Signed 

Purchaser 


Approved  .. 

Wilson  Welder  and  Metals  Company,  Inc. 


Approved 

Purchaser 


Executed....  191  . 


SPECIFICATIONS    FOR 

Electric  Arc  Welding  Motor-Generator  Sets 


CONSISTING  OF 


Direct  Current,  Compound,  Interpole  Generators  and 
Interpole,  Direct  Current  Motors 


GENERAL — The  machines  are  designed  and  built  with  special 
reference  to  the  intermittent  character  of  the  load  to  be  carried  and 
will  be  so  adjusted  as  to  operate  with  fixed  brushes  at  any  load  from 
no-load  to  maximum,  and  will  not  show  any  tendency  to  flash  when 
maximum  load  is  suddenly  removed. 

The  entire  magnetic  circuit  of  the  generator  is  constructed  of  thin 
sheet  steel  plates,  castings  being  used  only  for  mechanical  and  not  for 
magnetic  purposes,  thus  providing  an  extremely  quick  recovery  coefficient 
and  permitting  the  operation  of  more  than  one  welding  circuit  from  the 
generator  without  interference. 

The  commutation  will  be  sparkless  under  all  conditions  and  changes 
of  load  within  the  rating  of  the  machine  and  the  set  will  operate  without 
undue  noise  or  vibration. 

DATA 

Rated  Capacity  of  Generator 

in  Welding  Arcs 1  2  4  6  8 

Rated  Capacity  of  Generator 

in  Amperes 150  300  600  900  1200 

Rated   Capacity   of   Motor  in 

Horse  Power 7^  15  30  45  60 

Full  Load  Speed 1720  1200  1200  1200  1200 

Number  of  Poles  on  Motor  .    .4  4  4  4  4 

Number  of  Poles  on  Generator  44444 

Number  of  Interpoles    ....  4  4  4  4  4 

Voltage  of  Motor   ......          230  230  230  230  230 

Voltage  of  Generator     ....  35  35  35  35  35 

Temperature  Rise— Duty  Cycle  50°C  50°C  50°C  50°C          50°C 

Overall  Efficiencies  at 
Full  Load 
%  Load 
Yz  Load 
}4  Load 

Length  of  Set  in  Inches     .    .    .  49^  ^1A  77^  79^  88 

Width  of  Set  in  Inches  ....  14  18^  21%  28  28 

Weight  of  Set  in  Pounds  ...        1100  1750  2600  4200  4450 


CONSTRUCTION — The  Motor- Generator  Sets  will  consist  of  an  Inter- 
pole,  Direct  Current  Motor  and  35-Volt,  Direct  Current  Compound 
Wound,  Interpole  Generator,  mounted  on  a  heavy  cast  iron  subbase 
and  provided  with  self -oiling  bearings  lined  with  hard  genuine  babbitt. 

The  rotors  of  both  machines  being  mounted  on  a  single  shaft  of 
high  carbon  steel  supported  on  two,  three  or  four  bearings,  the  bearing 
housings  of  the  set  will  be  of  the  demountable  type  so  as  to  permit  the 
easy  removal  of  the  rotors. 

Compensators  equipped  with  a  No- Voltage  release  will  be  furnished 
with  each  set. 

Machines  will  be  of  the  protected  type  and  in  strict  accordance 
with  the  Standardization  Rules  of  the  A  I  E  E — Class  "A"  insulation 
being  used  throughout,  with  the  exception  of  the  commutators,  which 
will  be  mica  insulated. 

DIRECT   CURRENT   GENERATOR  AND   MOTOR 

FIELD — The  fields  will  be  of  the  ring  type,  constructed  of  laminated 
steel.  The  pole  pieces,  also  built  of  laminated  steel,  will  be  belted  in 
place  and  will  be  so  arranged  that  any  field  coil  and  its  core  may  be  easily 
removable.  The  field  coils  will  be  form  wound,  without  metal  spools, 
and  thoroughly  insulated. 

Both  machines  will  be  furnished  with  interpoles — one  for  each 
main  pole  on  the  machines — for  the  purpose  of  securing  improved 
commutation  and  fixed  brushes. 

ARMATURE — The  armatures  will  be  of  the  slotted  drum  type,  having 
a  core  of  thin  sheet  steel  of  high  magnetic  quality — each  sheet  being 
varnished  to  reduce  core  losses.  The  winding  will  be  of  formed  coils  or 
rectangular  bars  thoroughly  insulated  and  securely  held  in  place  by 
wedges  driven  into  grooves  between  the  tips  of  the  teeth,  or  by  mica 
insulated  band  wires,  and  when  necessary  by  binding  wire  over  the 
outer  ends  of  the  coils. 

The  commutators  will  be  built  of  hard  drum  copper  bars,  thoroughly 
insulated  with  mica  and  rigidly  held  in  place  by  heavy  clamping  rings. 

BRUSH  HOLDER — The  brush  holders  will  be  of  radial  type,  fitted 
with  carbon  brushes.  These  holders  have  no  sliding  contacts  which 
carry  current  and  the  brushes  are  easily  removable  from  the  machine. 

VENTILATION — Care  will  be  taken  to  provide  ample  ventilation  and 
where  necessary,  air  ducts  will  be  left  in  the  cores  so  that  free  circulation 
through  the  cores  and  windings  is  obtained.  An  exhaust  fan  will  be 
mounted  integral  with  each  armature  providing  axial  ventilation. 


WORKMANSHIP  AND   MATERIAL 

The  Wilson  Welder  and  Metals  Company,  Inc.,  guarantees  that  all 
material  and  workmanship  employed  under  this  specification  shall  be 
strictly  first  class  in  every  respect,  and  as  a  part  of  this  specification, 
both  physical  and  chemical  tests  of  material  used  is  appended. 


GUARANTEE 

The  Wilson  WTelder  and  Metals  Company,  Inc.,  guarantees  that  Motor 
Generator  Sets  built  under  this  specification  shall  be  strictly  first  class 
in  every  respect  both  mechanically  and  electrically,  and  if  after  instal- 
lation any  part  of  the  machine  discloses  weakness  or  unsuitability  for  the 
work  for  which  it  is  intended  on  account  of  defective  design,  material  or 
workmanship,  then,  and  in  that  event,  the  manufacturers  make  this  good 
without  expense  to  the  purchaser  any  time  inside  of  one  year  from  date 
of  installation  and  trial  test. 


Signed 

Wilson  Welder  and  Metals  Company,  Inc. 


Signed 

Purchaser 


Approved  

Wilson  Welder  and  Metals  Company,  Inc. 


Approved  

Purchaser 


Executed...  ....191  . 


Constant  Current  Control  Panel  for 
Welding  and  Cutting 


GENERAL  DESCRIPTION — The  general  function  of  this  panel  is  to 
maintain  a  constant  flow  of  current  between  the  welding  tool  and  the 
material  operated  on,  regardless  of  variations  in  the  resistance  of  the 
welding  circuit,  due  to  varying  lengths  of  arc,  or  other  causes. 

The  current  regulator  is  to  consist  of  a  carbon  pile  held  under 
compression  by  one  or  more  helical  springs,  the  pull  of  which  is  opposed 
by  a  solenoid  through  which  the  current  to  be  regulated  is  passed.  A 
suitable  air  dash  pot  is  to  be  connected  to  the  solenoid  plunger  to  pre- 
vent all  "hunting"  or  chattering,  due  to  the  tendency  of  the  plunger 
and  connected  parts  to  travel  beyond  the  desired  point. 

The  pressure  of  the  springs  is  to  be  transmitted  to  the  carbon  discs 
or  plates  through  a  lever,  and  the  springs  are  to  be  mounted  on  a  carriage 
in  such  a  manner  that  the  point  at  which  they  act  upon  the  lever  may  be 
changed,  thereby  increasing  or  decreasing  the  leverage.  The  position  of 
the  control  solenoid  with  regard  to  the  lever  is  to  be  fixed.  The  move- 
P  ment  of  the  spring  carriage  described  above  is  to  be  produced  by  a  small 
electric  motor,  so  wired  that  it  may  be  controlled  by  two  push  buttons 
located  at  the  welding  tool,  or  near  enough  to  the  welding  tool  so  that 
the  welding  operator  can  use  them  without  changing  his  position. 

The  panel  is  also  provided  with  a  reactance  coil  of  a  size  suffi- 
cient to  materially  assist  the  operator  in  maintaining  an  arc  with  a 
graphite  pencil  when  the  panel  is  used  for  "cutting"  or  burning  away 
metal  in  preparing  for  the  welding  process,  or  other  purposes. 

An  ammeter  is  provided  to  indicate  the  amount  of  current  used 
in  the  welding  process,  and  a  double  throw  switch  of  200  amperes 
capacity,  for  use  in  changing  from  the  welding  circuit  to  the  cutting 
circuit. 


EQUIPMENT — The  equipment  consists  of: 

1     Slate  panel   30"  x  40"  x  !*/£"   thick,   mounting. 

1  Current  regulator  complete  with  carbon  pile,  control  solenoid, 
pressure  springs,  dash  pot,  carriage  for  moving  pressure  springs,  and 
control  motor  to  produce  the  change  in  the  position  of  the  springs 
when  desired. 

1     200  Ampere  Ammeter. 

1     Reactance  coil  of  200  amperes  capacity. 

1  200  ampere,  250  volt,  double  pole,  double  throw  knife  switch  with 
fuse  connections  and  fuses  mounted  on  front  of  the  board. 

1  Electric  Vehicle  Association  Standard  50  Ampere  Type  "  N  "  Charging 
Receptacle. 

1  Hand  tool. 

1  Control  switch. 

1  50  Ampere  Electric  Vehicle  Association  Standard  Type  "N"  Plug. 

1  150  Ampere  Electric  Vehicle  Association  Standard  Type  "N"  Plug. 

WIRING — The  panel  will  be  completely  wired,  in  accordance  with 
the  attached  blueprint. 

All  wiring  and  all  material  used  in  making  the  connection  conform 
strictly  to  the  "National  Electrical  Code." 

REGULATION— While  the  welding  operator  maintains  an  arc  be- 
tween his  welding  tool  and  the  work,  the  control  panel  must  maintain 
the  current  constant  within  five  per  cent.  (5%)  of  the  mean  value,  re- 
gardless of  the  actual  value  of  current  that  is  flowing,  provided  the 
flow  is  between  the  limits  of  80  and  175  Amperes. 

RANGE  OF  CONTROL  —  The  range  of  current  is  from  80  to  175 
amperes. 

The  value  of  current  is  under  the  control  of  the  welding  operator 
wherever  he  may  be  working. 

CARBON  PILE — The  discs  or  plates  of  the  carbon  pile  are  composed 
of  clear  homogeneous  carbon,  with  parallel  faces,  and  to  be  of  uniform 
size  and  thickness. 

CARBON  PILE  MOUNTING — The  rods  which  support  the  carbon 
discs,  and  those  which  serve  as  guides  on  the  sides  of  the  pile,  are  to  be 
covered  with  an  insulation  material  presenting  a  smooth  no-abrasive 
surface  to  the  carbon  discs. 

SOLENOID — The  control  solenoid  is  to  be  insulated  both  between 
turns  and  between  the  coil  and  the  supporting  frame  with  asbestos 
insulations,  or  such  a  heat  resisting  insulation  as  will  positively  prevent 


the  coil  from  becoming  inoperative,  due  to  such  heat  as  may  be  gen- 
erated in  it  under  the  most  severe  conditions  encountered  in  the  use  of 
the  panel. 

V 

CONTROL  MOTOR — The  motor  for  controlling  the  position  of  the 
spring  carriage  is  to  be  a  series  wound  motor  so  wired  that  its  entire 
motion  in  either  direction  may  be  controlled  by  two  push  buttons  located 
at  a  distance. 

LIMITED  SWITCHES — Suitable  automatic  control  switches,  which 
will  stop  the  motor,  are  to  be  provided  to  prevent  the  spring  carriage 
from  travelling  too  far  in  either  direction. 

WORKMANSHIP  AND   MATERIAL 

The  Wilson  Welder  and  Metals  Company,  Inc.,  guarantees  that  all 
material  and  workmanship  employed  under  this  specification  shall  be 
strictly  first  class  of  their  respective  kinds  and  for  the  purpose  used. 


GUARANTEE 

The  Wilson  Welder  and  Metals  Company,  Inc.,  guarantees  that  the 
Motor-Generator  Sets  and  welding  and  cutting  panels  built  under  this 
specification  shall  be  strictly  first  class  in  every  respect  both  mechanically 
and  electrically,  and  if  after  installation  any  part  of  the  machine  dis- 
closes weakness  or  unsuitability  for  the  work  for  which  it  is  intended 
on  account  of  defective  design,  material  or  workmanship,  then,  and  in 
that  event,  the  Wilson  Welder  and  Metals  Company,  Inc.,  will  make  this 
good  without  expense  to  the  purchaser  any  time  inside  of  one  year  from 
date  of  installation  and  trial  test,  provided  the  entire  equipment  is 
operated  in  accordance  with  our  instructions  and  advice. 


Signed 

Wilson  Welder  «nd  Metals  Company,  Inc. 


Signed 

Purchaser 

Approved 

Wilson  Welder  and  Metals  Company,  Inc. 

Approved 

Purchaser 


30 


Portable   Equipments 
POWER   AND   HAND   MOVED 

FIELD  TYPE 

THIS  equipment  is  mounted  on  a  heavy  motor  truck  chassis 
with  a    high    power    internal  combustion  engine,  which  is 
suitable  for  use  where  it  is  necessary  to  move  an  equipment 
from  place  to  place  with  its  own  power. 

The  design  is  considered  a  desirable  one  for  the  Government  in 
connection  with  troop  trains  or  Commissary  Department,  when 
at  points  away  from  railway  lines.  It  would  also  be  suitable  around 
mining  plants,  and  in  connection  with  steamship  and  industrial 
work  in  cities  where  it  is  necessary  to  have  a  portable  equipment. 
The  design  is  shown  on  page  37  and  is  fully  described  in  speci- 
fication, pages  33-34.  This  equipment  complete  would  weigh  about 
8000  pounds,  which  includes  two  welding  panels  with  a  generator 
of  sufficient  capacity  to  supply  them,  arid  the  usual  amount  of 
accessories,  such  as:  tools,  extra  welding  metals,  etc. 

HAND  MOVED— SHOP  TYPE 

For  use  in  railway  shops,  industrial  concerns,  or  on  shipboard, 
where  it  is  desirable  to  move  a  welding  outfit  from  point  to  point, 
either  with  a  view  of  having  the  equipment  more  flexible,  or  for  the 
purpose  of  favoring  certain  wiring  plans,  we  have  prepared  a  port- 
able Shop  Type  equipment,  shown  on  page  38.  As  will  be  ob- 
served from  the  drawing  this  equipment  can  be  moved  by  hand  from 
point  to  point,  either  in  a  shop  or  on  board  ship.  The  weight  of  the 
truck  is  about  700  pounds,  and  with  a  two-arc  motor-generator  set, 
two  welding  panels,  and  the  usual  amount  of  wiring,  tools,  etc.,  the 
total  weight  would  be  about  3500  pounds. 

Our  specifications  and  guarantees  on  pages  21  to  30  inclusive 
cover  the  welding  equipment  contemplated  in  connection  with 
both  portable  sets. 


31 


THE  LAST  WORD  IN  ELECTRIC  WELDING 

Both  in  the  foregoing  and  following  pages  we  endeavor  to  present 
the  essential  facts  with  respect  to  our  Electric  Welding  System  and  trust 
we  have  fully  covered  the  ground. 

The  development  of  the  Wilson  System  as  outlined  herein,  represents 
years  of  research  and  experimental  work  both  as  to  design  and  construc- 
tion of  machines,  composition  of  metals  and  methods  of  use.  We  have 
not  discontinued  our  efforts  in  any  of  these  directions  and  shall  not,  for 
it  is  our  intention  to  retain 

THE  LEADERSHIP 

IN  THE 
ELECTRIC  WELDING  FIELD 

We  are  prepared  to  not  only  furnish  the  very  latest  and  best  Electric 
Welding  System  on  the  market,  but  stand  committed  to  a  solution  of 
such  problems  as  may  arise  in  the  progress  of  the  art,  and  to  this  end  we 
not  only  solicit  inquiries  from  ALL  our  patrons  and  friends,  but  extend 
to  them  our  services  in  any  matter  pertaining  to  the 

ELECTRIC  WELDING  ART 


SPECIFICATIONS   FOR 

Two  Ton  Worm  Drive  Chassis,  Portable 
Welding  Outfit 
"FIELD    TYPE" 


MOTOR  —  4  cylinder  —  4  cycle  —  25.6  H.  P.  A.  L.  A.  M.  4x5  inches. 
Unit  Power  Plant.  Sealed  governor.  Only  three  (3)  motor  gears; 
camshaft  gear,  crankshaft  gear  and  gear  for  driving  water  pump  and 
magneto.  Water  jacketed  inlet  manifold.  Twinned  exhaust  manifold. 

Inclosed  valves  oiled  by  breathers.  Pistons  removable  through 
bottom  crankcase. 


Three-inch  diameter  crank-shaft  bearings.     Connecting  rods 
inches  long. 

IGNITION  —  High  tension  magneto. 

LUBRICATION  —  Oil  fed  by  mechanically  driven  pump. 

FUEL  CONSUMPTION—  Under  ordinary  conditions,  will  travel  9  to 
10  miles  per  gallon  of  gasoline.  Tank  holds  20  gallons.  Uses  approxi- 
mately 1  gallon  of  lubricating  oil  for  every  180  miles. 

RADIATOR  —  "Honeycomb"  type.  Special  mounting  to  withstand 
vibration  due  to  solid  tires.  Water  circulation  by  gear-driven  pump. 
Belt-driven  fan,  mounted  on  roller  bearings.  Eccentric  belt  tightener. 

SPEED  (MAXIMUM)  —  High,  16  miles  per  hour;  medium,  9.11  miles 
per  hour;  low,  4.77  miles  per  hour;  reverse,  3.68  miles  per  hour. 

TRANSMISSION  —  Integral  with  motor.  Three  speeds.  Gears  of 
best  alloy  nickel  steel.  Run  on  "Timken"  bearings. 

DIFFERENTIAL  —  Is  in  the  rear  axle,  and  is  of  the  accepted  bevel 
gear  type.  Gears  are  nickel  steel,  specially  heat-treated. 

CONTROL  —  Very  simple  and  efficient.  Emergency  brake  and  gear 
shift  lever  on  power  plant  in  center  of  truck,  allowing  driver  to  manip- 
ulate them  easily  with  right  hand,  while  driving  truck  with  left. 


33 


CLUTCH — "Dry  plate"  type,  six  (6)  plates  lined  on  both  sides  with 
friction  material,  operating  against  six  (6)  plain  plates.  Very  successful 
type,  requiring  no  attention;  been  used  four  years. 

BRAKES — Internal  and  external  brake  on  brake  drums  16J4  inches  in 
diameter.  The  foot  brake  is  on  the  outside;  the  emergency  brake  on 
the  inside. 

STEERING — Steering  gear  is  on  the  left-hand  side  of  truck;  "worm, 
wheel  and  shaft"  type,  the  final  thrust  to  the  drag  link  being  through  a 
special  forging  on  a  squared  shaft  which  can  be  tightened. 

SPRINGS — Semi-elliptic:  front  and  rear.  Front  springs:  40  inches 
by  2J/2  inches — 8  leaves.  Rear  springs:  48  inches  by  3  inches — 11  leaves. 

AXLES — Front  axle  drop  forged  I-beam.  Hubs  fitted  with  "Tim- 
ken"  bearings,  complete. 

Rear  axle — Final  drive  through  a  "worm  and  gear"  rear  axle.  Full 
floating,  wheel  and  spring  load  being  taken  on  the  casing  entirely, 
only  the  drive  being  on  the  shafts  which  are  attached  to  the  hub  of  the 
wheel  on  the  outside.  Worm  and  wheel  are  of  special  composition  of  the 
well-known  "David  Brown"  type.  The  drive  is  taken  through  springs, 
in  this  way,  when  starting  under  heavy  load  new  surfaces  are  presented 
on  the  worm  and  wheel,  giving  the  drive  a  flexibility,  which  may  be  com- 
pared to  the  action  of  couplers  on  a  railroad  train.  The  mountings  of  the 
worm  and  worm  wheel  are  "Timken"  bearings;  the  wheel  bearings  are 
also  "Timken." 

WHEELS — Front:  Spokes  2  inches,  fitted  with  solid  rubber  tires 
36  inches  by  4  inches  single.  Rear:  Spokes  2^/2  inches,  fitted  with  solid 
rubber  tires  36  inches  by  4  inches  dual. 

WHEELBASE — 144  inches  and  162  inches — 58^  inches  tread.  Long 
wheel  base  will  turn  in  29-foot  radius;  short  wheel  base  will  turn  in 
25-foot  radius. 

FRAME — Special  pressed  steel  channel  section  of  ample  proportions 
made  very  strong  and  rigid  by  cross  members. 

FENDERS — Sheet  steel. 

DUST  PAN — Is  also  sheet  steel,  extending  from  radiator  to  rear  of 
transmission,  completely  housing  all  working  parts. 

EQUIPMENT — Open  metal  seat,  sliding  sidedoors,  horn,  lamps, 
spare  parts,  bumper,  etc. 


(INTERNATIONAL  MOTOR   COMPANY'S  TRUCK  DESIGN) 


34 


WELDING  METALS 

Our  specially  prepared  metal  electrodes  are,  unless  otherwise  ordered, 
Gage  9.  5-32,  .1483  on  list  below. 


FULL  SIZES  OF  PLAIN  WIRE 


Sizes  of  Wire 


Steel 
Wire 
Gage 
No. 


10 

11 

12 
13 
14 
15 
16 
17 
18 
19 
20 


Com- 
mon 
Frac- 
tions 


9-32 


1-4 


7-32 


3-16 


5-32 


1-8 


3-32 


1-16 


Deci- 
mally 


.2830 
.28125 

.2625 
.250 

.2437 


.2253 
. 21875 
.2070 

.1920 
.1875 
.1770 

.1620 
. 15625 
.1483 

.1350 

.1250 

.1205 

.1055 

. 09375 

.0915 

.0800 
.0720 
.0625 
.0540 
.0475 
.0410 
.0348 


Weight 
One 
Mile 

Pounds 


1128.0 
1114.0 

970.4 

880.2 

836.4 


714.8 
673.9 
603.4 

519.2 
495.1 
441.2 

369.6 
343.8 
309.7 

256.7 
220.0 
204.5 
156.7 
123.8 
117.9 

90.13 

73.01 

55.0 

41.07 

31.77 

23.67 

17.05 


Pounds 
Per 
Foot 


.2136 
'.211 

.1838 
.1667 

.1584 


.1354 
.1276 
.1143 

.0983 
.0937 
.0835 

.070 

.0651 

.0586 

.0486 
.0416 
.0387 
.0296 
.0234 
.0223 

.0170 

.0138 

.0104 

.0077 

.006 

.0044 

.0032 


(FROM  AMERICAN  STEEL  AND  WIRE  COMPANY) 

We  furnish  the  following  grades: 


Grade  No. 

Purpose  Used 

Tensile  Strength 
of  Welds 

6 

Boilers 

8 

Can  be  Machined 

40,000 

9 
17 
20 

Engine  Frames,  etc. 
Filling  Castings,  etc. 
Bronze  Alloy  Bells,  etc. 

to 
60,000 
Pounds 

These  metals  unless  otherwise  arranged  for,  are  of  Gage  9,  approxi- 
mately 5-32  inch  diameter  and  are  shipped  in  coils  of  about  160  pounds 
weight.  When  customers  order  electrodes  cut,  straightened  and  boxed, 
or  of  dimensions  less  than  .148,  an  extra  charge  is  made. 

No  Fluxes  are  used  with  our  metals. 


35 


A  Complete  Electric  Welding  Equipment 

of  the  Wilson  System  Consists 

of  the  Following 


INCLUDED  IN 
WELDER  COMPANY'S 

SCHEDULE  OF 
EQUIPMENT  FURNISHED 


Not  INCLUDED  IN  WELDER 
COMPANY'S  SCHEDULE  OF 

EQUIPMENT,  BUT  SHOULD  BE 
PROVIDED  BY  PURCHASER 


Motor  Generator  Set. 

Starting  Box.  Oil-immersed.  No- vol- 
tage release. 

Control  Panel  for  each  arc  of  capacity, 
with  Angle  Iron  Supports  and  Bolts  for 
fastening. 

Ammeter  on  each  Panel. 

Plugs  for  attaching  welding  and  control 
leads  to  Panel. 

Electrode  holder  for  each  Panel. 

One  push  button  control  to  each  holder. 

About  ten  feet  of  flexible  welding  cable. 

Operator's  Helmets  or  Shields. 
Extra  piece  of  colored  glass. 
Steel  Brushes. 

Supply  of  welding  metals  of  different 
grades. 


We  furnish  welding  equipments  of  the  following  size  and  capacity: 


CAPACITY 

Arc  or 

Voltage 

of 

Operators 

Amperes 

(Fixed) 

Panels 

Prices  Furnished  on 

1 

150 

35 

1 

Request 

2 
4 

300 
600 

35 
35 

2 
4 

Correspondence  Solicited 

6 

900 

35 

6 

8 

1200 

35 

8 

PATENTS 

The  Wilson  System  of  Electric  Welding  and  Specially  Prepared 
Welding  Metals  is  protected  by  United  States  and  Foreign  Patents. 


36 


Results  Obtained  from  the  Use  of  the 
Wilson  System 


Having  reviewed  the  development  of  the  Wilson  System  of  Electric 
Welding  and  Special  Metals,  with  photographs,  drawings  and  speci- 
fications of  the  equipment  in  the  preceding  pages,  we  now  invite  your 
attention  to  certain  results  obtained  from  their  use  both  in  the  matter 
of  High  Character  of  Finished  Product  and  Economy  of  Operation. 


No. 

Examples  of  Character  of  Work  Involved  and 
Saving  Effected 

Cost 

Amount 
Saving 

See 
Page 

1 

2 

Reclamation  of  Pneumatic  Hammer  Handle  .... 
Car    Repair  Yards   and  Maintenance  of  Way  Dept. 
Saving  on  three  jacks 

$   .76 
44 

$3.16 
3  26 

42 
43 

3 
4 

Reclamation  of  Locomotive  Bell  (Bronze)     .... 
Walking  Beam  of  Circulating  Pump,  U.  S.   S.   S. 
"Dray  ton" 

2.60 
2  25 

7.50 
1750 

44 
44 

5 
6 

7 
8 
9 

Building  up  Flat  Spots  on  Locomotive  Drivers   .    .    . 
Reclamation  of  Locomotive  Cylinder  
Saving  in  Expensive  Tool  Steels  (1000  Tools)   .    .    . 
Reclamation  of  Freight  Car  Knuckles.  (Per  year) 
Union  of  Various  Sections  of  Steel,  Wrought  and 
Cast  Iron  ... 

2.00 
63.48 
1.360 

4.897 

Samples 

200.00 
401.27 
7,360.00 
26,000.00 

Samples 

46 
45 
42 
43 

43 

10 

Variety  of  Operations  possible  at  one  and  the  same  time 

Multiple 

Unit 

46 

The  foregoing  represent  only  a  few  of  the  hundreds  of  operations 
that  are  being  daily  performed  by  the  Wilson  Welder  which  result  in 
great  economy,  both  in  the  items  of  initial  cost  and  increased  earning 
power  of  equipment,  due  to  reduced  dead  time  while  undergoing  repairs. 

On  the  next  following  pages  will  be  found  photographic  reproductions 
of  some  of  the  operations  mentioned. 


41 


No.  1     Reclamation  of  Pneumatic  Hammer  Handle 


No.  2     Cutting  Tools  Ready  for  Welding  Points 


No.  3     Cutting  Tool  Points  Welded  on 


No.  4    Cutting  Tools  Ready  for  Use 
Cuts  2,  3  and  4  show  the  application  of  high  grade  cutting  points  to  low  carbon  tools 


Boiler  Plate  Welds  that  Never  Break 


Samples  of  Welded  Cast  Iron  and  Steel,  Wrought  Iron  and  Boiler  Plate 


Reclamation  of 
Track  and  Shop  Jacks 

Cost  -   -  $  .44 
Saving  -  $3.26 


Reclamation  of  Freight  Car  Knuckles  on  a  Trunk  Line.     The  saving  in  one  year 
on  this  item  alone  was  more  than  $20,000.00. 


43 


« 


6    a 
8  '> 

j    c£ 


s? 

I  s 

1 1 


44 


Repairs 

being  made 

with  Wilson 

Electric  Welder 


Fractured 
Steam  Chest 

and 
Cylinder 


Damaged  Parts 
Restored  Good 

as  New 

Cost,  $63.48 
Saving,  $401.27 


Reclamation  of  Fractured  Cylinder  and  Steam  Chest  on  Modern  Pacific  Type  Locomotive 


Building  up  Flat  Spots  on  Locomotive  Drivers.  Cost  $2.00;     Saving  $200.00 


Variety  of  operations  at  one  and  the  same  time.  Four  operators  welding  four 
different  metals,  each  with  a  different  amperage  from  a  single  Generator  at  the  same 
time  and  without  interfering  with  each  other. 


46 


Physical  Tests  of  Electrically 
Welded  Joints 


Wilson  Electric  Welding  has  been  subjected  to  the  severest  kinds  of 
tests.  Among  these  are  included  heat  treatment,  vibratory  tests,  tor- 
tional  and  twisting  strains  of  all  kinds,  crushing  tests,  tensile  strength 
tests,  etc. 

The  figures  shown  in  following  tables  were  obtained  by  taking  a 
piece  of  rectangular  boiler  plate  18  by  20  inches,  of  known  minimum 
tensile  strength,  cutting  through  center  the  long  way  and  welding  with 
the  grade  of  welding  wire  suitable  for  this  purpose.  These  plates  were 
then  cut  into  test  pieces  one  and  one-half  inches  wide  and  tested  in  the 
regular  way  in  a  physical  testing  machine. 

The  results  shown  below  are  the  average  of  many  hundred  tests 
made  by  this  company  to  determine  the  proper  quality  of  welding  wire 
to  use  for  this  purpose. 


Test 
No. 

CURRENT 

AREA 

Breaking 
Load 

Tensile 
Strength  per 
Sq.  In.  Weld 

%  Elonga- 
tion in 
2  In. 

Volts 

Amps 

Plate 

Weld 

1 

35 

95 

.532 

.532 

28140 

52900 

6.25 

2 

35 

95 

.544 

.544 

28250 

52000 

4.25 

3 

35 

95 

.546 

.546 

30450 

55800 

7.80 

4 

35 

95 

.558 

.558 

31070 

55700 

7.80 

5 

35 

95 

.555 

.555 

31200 

56200 

6.25 

6 

35 

95 

.566 

.566 

31000 

54800 

6.25 

7 

35 

95 

.578 

.578 

32100 

55000 

6.25 

8 

35 

95 

.585 

.585 

33050 

56500 

7.80 

9 

35 

95 

.585 

.585 

30300 

51800 

6.25 

10 

35 

95 

.602 

.602 

30630 

50900 

6.25 

11 

35 

95 

.589 

.589 

32000 

54300 

7.80 

12 

35 

95 

.540 

.540 

31640 

58600 

7.80 

Average 

35 

95 

.565 

.565 

30820 

54500 

6.90 

NOTE:— Above  test  pieces  planed  flush  with  sheet. 


47 


Test 
No. 

CURRENT 

AREA 

Breaking 
Load 

Tensile 
Strength  per 
Sq.  In.  Weld 

4. 

%  Elonga- 
tion in 
2  In. 

Volts 

Amps. 

Plate 

Weld 

1 

2 
3 
4 
5 
6 
7 
8 
9 
10 
11 

35 
35 
35 
35 
35 
35 
35 
35 
35 
35 
35 

80 
80 
80 
80 
80 
80 
80 
80 
80 
80 
80 

.630 
.615 
.637 
.616 
.617 
.616 
.622 
.665 
.638 
.630 
.621 

.630 
.615 
.637 
.616 
.617 
.616 
.622 
.665 
.638 
.630 
.621 

32490 
34000 
33200 
35320 
35610 
34650 
35370 
35230 
35530 
33890 
34210 

52800 
53300 
53800 
57200 
57800 
52200 
56800 
53300 
55600 
53700 
55100 

6.25 
6.25 
6.25 
6.25 
9.38 
9.38 
7.80 
6.25 
9.38 
7.80 
9.38 

Average 

35 

80 

.628 

.628 

34500 

54700 

7.67 

NOTE:  —  Above  test  pieces  had  weld  planed  flush  with  plate;   test  Nos.  5,  7,  8  and  9 
broke  outside  of  weld. 

Test 

No. 

CURRENT 

AREA 

Breaking 
Load 

Tensile 
Strength  per 
Sq.  In.  Weld 

%  Elonga- 
tion in 
2  In. 

Volts 

Amps. 

Plate 

Weld 

1 

2 
3 
4 
5 
6 
7 
8 
9 

35 
35 
35 
35 
35 
35 
35 
35 
35 

100 
100 
100 
100 
100 
100 
100 
100 
100 

.517 
.548 
.555 
.556 
.552 
.579 
.569 
.579 
.576 

.517 
.548 
.555 
.556 
.552 
.579 
.569 
.579 
.576 

30700 
30600 
30900 
30600 
29000 
29200 
40000 
40000 
40200 

59300 
56000 
55700 
55000 
52500 
50400 
56500 
55400 
55200 

9.38 
9.38 
7.80 
9.38 
7.80 
7.80 
7.80 
7.80 
7.80 

Average 

35 

100 

.562 

.562 

35100 

55200 

8.53 

NOTE:—  Test  piece  No.  3  broke  outside  of  weld. 

Test 
No. 

CURRENT 

AREA 

Breaking 
Load 

Tensile 
Strength  per 
Sq.  In.  Weld 

%  Elonga- 
tion in 
2  In. 

Volts 

Amps. 

Plate 

Weld 

1 

2 
3 
4 
5 
6 
7 
8 
9 
10 
11 

35 
35 
35 
35 
35 
35 
35 
35 
35 
35 
35 

90 
90 
90 
90 
90 
90 
90 
90 
90 
90 
90 

.610 
.615 
.599 
.604 
.611 
.622 
.592 
.602 
.598 
.592 
.585 

.610 
.615 
.599 
.604 
.611 
.622 
.592 
.602 
.598 
.592 
.585 

31360 
34840 
34640 
35090 
33810 
32680 
33840 
34770 
33620 
33010 
32830 

51400 
56600 
57800 
58000 
55300 
52600 
57200 
57600 
56100 
55900 
56100 

7.80 
9.38 
9.38 
9.38 
10.90 
6.25 
9.38 
9.38 
7.80 
7.80 
10.90 

Average 

35 

90 

.603 

.603 

33680 

55800 

8.94 

NOTE:—  Above  test  pieces  had  weld  planed  flush  with  plate;  test  Nos.  2,  4,  5,  8  and 
9  broke  outside  weld. 

48 


CURRENT 

AREA 

Tensile 

%  Elonga- 

Test 

Breaking 

Strength  per 

tion  in 

No. 

Load 

Sq.  In.  Weld 

2  In. 

Volts 

Amps. 

Plate 

Weld 

1 

35 

80 

.538 

.538 

31540 

58600 

10.90 

2 

35 

80 

.545 

.545 

29500 

54200 

10.90 

3 

35 

80 

.605 

.605 

33000 

54600 

10.90 

4 

35 

80 

.615 

.615 

34440 

56000 

9.38 

5 

35 

80 

.584 

.584 

33640 

57500 

9.38 

6 

35 

80 

.589 

.589 

34600 

58700 

9.38 

7 

35 

80 

.590 

.590 

33800 

57300 

9.38 

8 

35 

80 

.595 

.595 

33600 

56500 

10.90 

9 

35 

80 

.488 

.488 

27800 

57000 

9.38 

Average 

35 

80 

.572 

.572 

32400 

56700 

10.00 

NOTE:  —  In  above  tests,  Nos.  1,  3,  4  and  6  broke  outside  of  weld. 

CURRENT 

AREA 

Tensile 

%  Elonga- 

Test 

Breaking 

Strength  per 

tion  in 

No. 

Load 

Sq.  In.  Weld 

2  In. 

Volts 

Amps. 

Plate 

Weld 

1 

35 

80 

.612 

.612 

36100 

59000 

9.37 

2 

35 

80 

.585 

.585 

33300 

56900 

6.25 

3 

35 

80 

.605 

.605 

36000 

59500 

7.81 

4 

35 

80 

.589 

.589 

35600 

60400 

7.81 

5 

35 

80 

.605 

.605 

35100 

58000 

7.81 

6 

35 

80 

.598 

.598 

35700 

59700 

9.37 

7 

35 

80 

.597 

.597 

35800 

60000 

6.25 

8 

35 

80 

.582 

.582 

35000 

60100 

7.81 

9 

35 

80 

.600 

.600 

34800 

58000 

7.81 

10 

35 

80 

.588 

.588 

35000 

59500 

6.25 

11 

35 

80 

.580 

.580 

32700 

56400 

6.25 

Average 

35 

80 

.595 

.595 

35000 

58900 

7.53 

NOTE:  —  Above  test  pieces  all  planed  down  flush  with  plate;  test  Nos.  3,  4,  7,  8  and 
10  broke  outside  weld. 

The  above  experiments  conducted  on  standard  firebox  steel  demon- 

strate that  by  the  use  of  the  Wilson  Electric  Welding  process,  practically 

a  100  per  cent,  efficient  seam  is  secured. 

' 

49 


CCOA/O/W 


COST 


(OO 


$2.00 


$3.00 


0.89 


$4/0 


No.  1. 


EXPLANATORY  NOTES 

Wilson  type  of  machine,  35   volts,   90  amperes,  positive  heat 
control  arc. 


No.  2.  Variable  voltage  constant  current  machine  with  no  resistance  in 
circuit,  80  volts  with  no  load  and  20  to  25  volts  with  load,  150 
amperes. 

No.  3.  Constant  voltage  machine,  fixed  resistance  control  of  current, 
65  volts,  125  to  175  amperes. 

No.  4.  Constant  voltage  machine,  fixed  resistance  control  of  current, 
using  75  volts,  125  to  175  amperes. 

No.  5.  Constant  voltage  machine,  fixed  resistance  control  of  current, 
using  90  volts,  125  to  175  amperes. 

The  object  of  the  development  of  the  Wilson  System  of  Electric 
Welding  was  primarily  to  overcome  defective  welds  and  secondarily  to 
reduce  cost  of  operation.  There  are  still  many  machines  of  the  No.  5 
type  in  service. 

In  a  competitive  test  on  a  trunk  line  railroad  recently  the  Wilson 
System  and  Metals  proved  to  be  superior  to  others  on  the  following 
items  in  welding  boiler  tubes. 

Total  amount  of  metal  deposited 87.22% 

Net  time  per  pound  of  metal  applied  .  .  .  .  45 . 4  % 
Kilowatts  per  pound  of  metal  applied  .  .  .49.35% 
Ounces  of  metal  per  flue 72.2  % 

This  is  spelling  ECONOMY  with  capital  letters. 


50 


A  Lesson  in  Preparedness 

SOME   COLD   FACTS 

THE  REVENUES  OF  OUR  RAILWAYS  LAST  YEAR  WERE  $3,030,346,306.00 

This  money  was  earned  by  about  63,000  freight 

and    passenger   locomotives,    or   an    average   per 

engine  per  year  of  ..............  $48,107.00 

Average  per  day      ..............  $131.77 

THE  REVENUE  FROM  FREIGHT  WAS  ........  $2,114,697,629.00 

This  was  earned  by  about  34,000  locomotives,  or 

an  average  per  year  of  ............  $62,197.00 

Average  per  day      ..............  $170.00 

MILEAGE  OF  FREIGHT  LOCOMOTIVES  FOR  THE  YEAR 

WAS   .....................        695,276,668.00 

(  per  year     .....    20,449 


[  per  hour     .....          2.3 

From  the  foregoing  it  is  clear  that  the  average 
return  from  a  freight  engine  is  $170.00  per  day,  or 
$7.08  per  hour,  for  24  hours,  while  if  we  assume 
they  are  in  service  10  hours  of  each  24,  then  the 
earning  value  per  hour  is    ..........  $17.00 

As  there  are  hundreds  of  freight  engines  regularly 

making  more  than  3,000  miles  per  month,  or  100 

miles  per  day,  then  the  low  average  of  1,704  miles 

per  month  and  only  56  miles  per  day  is  the  result 

of  a  large  number  being  in  the  shop  for  repairs. 

On  a  certain  Trunk  line  it  is  estimated  the  cost  to 

work  flues  applied  in  the  old  way  is  about  $54.00 

per  engine,  per  year,  while  for  those  electrically 

welded,  the  cost  is  $15.00  for  welding  and  nothing 

for   repairs.      Net    saving   approximately    $39.00 

per  year,  and  on  100  engines   .........  $3,900.00 

Assuming  the  number  of  engine  hours  lost, 
account  working  flues  to  be  three,  and  that  this 
is  necessary  twice  each  month,  we  then  have  3  x 
$17.08x24  =  $1,229.76  per  year  for  one  engine 
and  on  100  engines,  loss  of  earning  power  .  .  .  $122,976.00 

f  Increased    Earning 
CREDIT  ELECTRIC  WELDING  j       Power     ......  $122,976.00 

(  Saving  in  Repairs     .    .  3,900.00 


Total $126,876.00 

On  this  subject  a  word  to  the  Wise  is  sufficient.  The  cost  of  repairing 
flues  between  setting  and  the  loss  of  earning  power  of  engines  due 
to  flue  failures  can  be  eliminated  by  the  use  of  an  Electric  Welder. 
No  other  investment  will  yield  the  same  returns,  but  there  are 
many  other  operations  in  railway  maintenance  that  will  yield  to 
the  same  treatment  and  with  like  results. 


51 


USEFUL  INFORMATION 

WEIGHTS  AND  MEASURES 


LINEAR  MEASURE 


12 
3 


40 

8 


Inches     =1  Foot 
Feet         =  1  Yard 
Yards      =1  Rod 
Rods        =1  Furlong 
Furlongs  =  1  Mile 

SQUARE  MEASURE 


In. 

36 

198 

7920 


Ft. 

3 

16.5 
660 


63360       5280       1760       320 


Yd.       Rd.     Fur.    Mi. 


1 

5.5         1 

40          1 

8 


144      Sq.  Inches 

9      Sq.  Feet 
30^  Sq.  Yards 
160      Sq.  Rods 
640      Sq.  Acres 


=  1  Sq.  Foot 
=  1  Sq.  Yard 
=  1  Sq.  Rod 
=  1  Acre 
=  1  Sq.  Mile 


AVOIRDUPOIS  WEIGHT 

437.5  Grains  =1  Ounce 

16      Ounces  =1  Pound 

100      Pounds  =1C.  W.  T. 

20      C.  W.  T.  =lTon 

2240      Pounds  =  1  Long  Ton 

DRY  MEASURE 

2  Pints  =  1  Quart 

8  Quarts  =  1  Peck 

4  Pecks  =  1  Bushel 

2150.42  Cu.  Ins.  =1  Bushel 


CUBIC  MEASURE 

1728      Cubic  Inches  =1  Cu.  Ft. 

27      Cubic  Feet  =  1  Cu.  Yd. 

128      Cubic  Feet  =lCord 

24%  Cubic  Feet  =  1  Perch 


TROY  WEIGHT 

24  Grains  =  1  Penny  Weight 

20  Penny  Wt.  =  1  Ounce 

12  Ounces  =  1  Pound 

1  Pound  =5760  Grains 


LIQUID  MEASURE 


4      Gills 
2      Pints 
4      Quarts 
31 J^  Gallons 
2      Barrels 


=  1  Pint 
=  1  Quart 
=  1  Gallon 
=  1  Barrel 
=  1  Hogshead 


ELECTRICAL   UNITS 

The  electrical  units  are  derived  from  the  following  mechanical  units 
of  the  Metric  System. 

Centimeter — Unit   of   length.      One   thousand    millionth   part   of   a 
quadrant  of  the  earth's  circumference. 

Gramme — Unit  of  weight.     Weight  of  a  cubic  centimeter  of  water 
at  temperature  of  4  degrees  centigrade. 


52 


Second — Unit  of  time.  The  time  of  one  swing  of  a  pendulum  making 
86,400  swings  in  a  solar  day. 

The  unit  of  area  is  the  square  centimeter.  The  unit  of  volume  is 
the  cubic  centimeter. 

Volt — Unit  of  electro-motive  force :  Pressure  of  potential.    Symbol  E. 

Ohm — Unit  of  resistance.     Symbol  R. 

Megohm— 1,000,000  Ohms. 

Ampere — Unit  of  current.     Symbol  C. 

Ampere-hours — Current  in  amperes  by  time  in  hours. 

Watt — Unit  of  power.  Product  of  1  volt  by  1  ampere.  Symbol  W. 
(746  watts  equal  one  horse  power). 

Horsepower — 746  watts  =  33, 000  Ibs.  one  foot  in  one  minute. 

Kilowatts— 1,000  watts.    Symbol  K.W. 

Kilowatt-hours — Kilowatts  by  time  in  hours  =  1.341  H.P.  hours. 

Farad — Unit  of  capacity. 

Microfarad — One-millionth  of  a  farad.     Written  M.F. 

Coulomb — Unit  of  quantity.  Quantity  of  current  which  impelled 
by  one  volt  would  pass  through  one  ohm  in  one  second. 

Joule — Unit  of  work.     The  work  done  by  one  watt  in  one  second. 

Mils  and  Circular  Mils — The  one-thousandth  part  of  one  inch. 
Written  .001  and  usually  called  one  mil,  is  taken  as  the  unit  of  diameter, 
from  which  one  square  mil  would  be  the  unit  of  area.  If  you  measure 
the  diameter  of  a  round  wire  in  thousandths  of  an  inch,  or  mils,  by  means 
of  a  micrometer,  and  multiply  this  number  by  itself,  i.e.,  square  it,  you 
obtain  in  square  mils  the  cross  sectional  area  of  a  square  wire  having 
four  sides,  each  the  same  length  as  the  diameter  of  the  round  wire  that 
you  have  calipered. 

Circular  Mil — (Usually  written  C.M.)  Applies  to  all  round  wires 
and  has  a  value  .7854  times  that  of  the  square  mil. 

Consequently  the  square  of  the  diameter  of  any  round  wire,  measured 
in  mils,  gives  its  cross  sectional  area  in  circular  mils,  without  any  further 
multiplication . 

FORMULA  FOR  SHOP  WIRING 

A  good  formula  for  wiring  circuits  for  electric  equipments  will  be 
found  at  the  bottom  of  wiring  table,  pages  54-55. 


53 


Examples  of  Wire  Calculations 

To  find  the  size  of  wire  required  to  carry  100  Amperes  500  feet  with 

5  volts  drop: 

FORMULA  A 

p  M  _  Feet  x  Amperes  x  10.7 
Volts  Drop 

500  x  100  x  10.7  =107X)()0  C_M_ 


Therefore  the  nearest  standard  wire  required  as  per  tables  attached 
is  No.  0  which  is  a  106.000  C.M. 


FORMULA  B 

To  find    the  volts  drop  having  the  distance  of  1000  feet  No.  0000 
B.  &  S.  gauge  wire  and  a  current  of  100  Amperes. 

Feet  x  10.7  x  Amperes 
Volts  drop  =  CM 


1000  x  100x10.7      K 
drop  =          212.000       ~=5 


FORMULA  C 

To  find  the  current  in  Amperes  which  a  No.  000  gauge  wire  will 
carry  500  feet  with  a  5  volt  drop. 

C.M.  x  Volts  drop 
Amperes  =         10.7  x  Feet 

168.000x5 


Note. — Above  formulas  are  correct  when  the  return  is  approximately  Zero  resist- 
ance, such  as  bonded  Railroad  tracks,  steel  frame  work,  &c.  If  metallic  return  is  to  be 
used  then  double  the  C.  M. 


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USEFUL    INFORMATION 


SPECIFIC  GRAVITY  AND  FUSING  POINT  OF  METALS 


Metal 

Specific 
Gravity 

Weight  per 
Cubic 
Foot 

Melting 
Point 
Fahrenheit 

Value 
pel- 
Ton 

1 

Aluminum    

2.67 

166.5 

1175 

$1,000 

2 

Antimony    

2.76 

421.6 

1160 

852 

3 

Brass    

8.40 

523.8 

1650 

360 

4 

Bronze      

8.85 

552 

1692 

420 

5 

Cobalt  

8.55 

533.1 

6000 

4,000 

6 

Gold  Pure    

19.26 

1201 

1935 

41,340 

7 

Copper     

8.85 

552 

1940 

480 

g 

Iridiurn 

22.38 

1396 

4280 

g 

Iron,  Cast  —  Pig  

7.21 

450 

2200 

19 

10 

Iron,  Wrought  —  Bars    .    .    . 

7.70 

480 

2900 

50 

11 

Lead     

11.38 

709.7 

620 

120 

12 

Manganese  

8 

499 

6000 

120 

13 

Mercury  

13.58 

846 

38 



14 

Nickel  

8.8 

548.7 

2600 

900 

15 

Platinum      

21.5 

1347 

3110 

200,000 

l(j 

Silver    

10.50 

655 

1800 

1,330 

17 

Steel,  O.  H  

7.85 

489 

2600 

45 

18 

Tin    

7.35 

458 

449 

840 

19 

Tungsten 

17.3 

1078.7 

5252 

20 

Zinc  

7 

436.5 

786 

480 

SPECIFIC  GRAVITY  AND  WEIGHT  PER  CUBIC  FOOT  OF  VARIOUS  SUBSTANCES 


Substance 

Specific 
Gravity 

Wt.  per 
Cu.  Ft. 

Substance 

Specific 
Gravity 

Wt.  per 
Cu.  Ft. 

1 

2 

Asphalt     
Brick    

1.39 
1.79 

87 
112 

21  Lignum  Vitae    .    . 
22  Oak  Heart     .    .    . 

1.333 
1.170 

83 
73 

3 

Cement    

1.42 

90 

23  Orange   

.705 

44 

4 

Cement,  Portland  . 

2.90 

180 

24  Poplar    ... 

.383 

24 

5 

Clay      

2.00 

135 

25  Pine  Yellow  .    . 

.660 

41 

6 

Earth    

1.20 

75 

26  Walnut  

.671 

42 

7 

Emery  

4 

250 

27  Alcohol  

.792 

49 

8 

Glass     

2.60 

165 

28  Beer,  Lager   .    .    . 

1.034 

64 

9 

Granite 

1.8 

110 

29  Champagne 

.997 

62 

10 

Gypsum   

2.2 

140 

30  Honey    

1.450 

90 

11 

Hornblend   .... 

3.4 

210 

31  Human  Blood  .    . 

1.054 

65 

12 

Ice     

.88 

56 

32  Petroleum      .    .    . 

.825 

51 

13 

Limestone    .... 

2.5 

160 

33  Linseed  Oil    ... 

.940 

59 

14 

Magnesia     .... 

2.4 

150 

34  Olive  Oil    .... 

.915 

57 

15 

Marble     

2.7 

170 

35  Whale  Oil  .... 

.932 

58 

16 

Mica     

2.8 

175 

36  Tallow,  Sheep  .    . 

.924 

56 

17 

Pitch    

1.15 

72 

37  Water,  Dead  Sea  . 

1.240 

77 

18 

Plaster  Paris    .    .    . 

1.70 

100 

38  Water,  Distilled    . 

1.000 

62 

19 

Slate     

2.79 

175 

20 

Quartz  

2.64 

165 

57 


HIGH  TEMPERATURES  JUDGED   BY  COLORS 

(Kent) 


Colors 

4 

Centigrade 

Fahrenheit 

1     Red,  visible  in  dark   
2    Red,  visible  in  twilight      

400 
474 

752 

885 

3    Red,  visible  in  daylight     

525 

975 

4     Red,  visible  in  sunlight     

581 

1070 

5     Dark  red 

700 

1292 

6     Cherry  red  
7     Bright  cherry-red    
8     Orange-red  
9     Orange-yellow     
10     Yellow-white  
11     White  welding-heat    
12    Brilliant  white    •  .    . 
13     Dazzling  white  (bluish-white)  

900 
1000 
1100 
12QO 
1300 
1400 
1500 
1600 

1652 
1832 
2012 
2192 
2372 
2552 
2732 
2912 

VARIOUS  TEMPERATURES  OF  FURNACES 

(Reprint  from  King  Optical  Co.) 


Process 


Fahrenheit 


Electric  Arc 

Electric  Arc  under  pressure  .... 

Oxy-Hydrogen 

Oxy-Acetylene  Welding  and  Cutting 

Thermit  Welding 

Metal  at  Tuyeres  (B.  F.'s)   .    .    .    . 

Metal  at  Tapping  . 

O.  H.  Furnace  Flame 

Bessemer  Converter 

Open  Hearth  in  Ladle 


Soaking  Pits — Low  Carbon  .... 
Soaking  Pits — High  Carbon  .  .  . 

Gas  Heating  Furnace 

Large  Gas  Heating  Furnace  .  .  . 
Heat  Units  Petroleum,  pound  .  . 
Heat  Units  Anthracite  Coal,  pound 
Heat  Units  Bituminous  Coal,  pound 

Heat  Units  Coke 

Heat  Units  Wood  . 


6200 

6450 

3600 

4350 

4500 

3500 

2300-2800 

3400-3600 

3400-3600 

2800-2900 

2800-2900 

2500-2600 

2200 

2400-2800 

2900-3200 

20000 

15000 

14500 

13500 
8000 


58 


How  We  Have  Been  Received 


The  Wilson  Welder  and  Metals  Company  was  organized 
December,  1915,  and  at  that  time  executed  the  first  order  which  was 
for  a  single  arc  welder  of  the  belted  type.  During  the  first  ten 
(10)  months  of  operation  the  results  have  been  most  flattering, 
constituting  as  they  do  a  strong  endorsement  of  the  Wilson  System. 


Railway  mileage  covered  by  first  order 60 

Railway  mileage  covered  by  first  ten  months'  orders      57,634 
Mileage  Increase 57,574  miles 


Among  our  list  of  customers  will  be  found  the  largest  and  best 
railway  systems  in  America  reaching  from  the  Atlantic  to  the 
Pacific  and  from  Canada  to  the  Gulj  of  Mexico  and  to  these  may 
be  added  The  United  States  Government  and  the  two  largest  Loco- 
motive Works  in  the  World. 

THE   ABLEST  CRITICS  HAVE  SPOKEN  AND  WE 
ACCEPT   THEIR   VERDICT 


59 


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61 


INDEX 

SUBJECT  PAGES 

Title  page 4 .    .  3 

Officers  and  Directors ^ 

Why  This  Book  is  Published 5 

Contents      6 

Development  of  Wilson  System 7 

Superiority  of  Equipment  and  Metals 8-9 

Photographs  of  Electrode  Holder,  A.  C.  and  D.  C.  Starting  boxes 

with  no-voltage  release 10 

Announcement  of  Photographs  and  Specifications 11 

Motor-Generator  Sets— Four  Arc  A.  C.  and  D.  C 12 

Control  Panel  with  List  of  Parts. 13 

Six  Panel  Installation.    American  Locomotive  Company   ....  14 
Wiring  Diagram  of  Wilson  Welding  Panel  Control  Switch,  and 

Electrode  Holder 15 

Catalogue  of  Parts  of  Welding  Generators  and  Motors 16 

Sectional  View  A.  C.  Motor-Generator  Four  Arc  Capacity   ...  17 

Sectional  View  D.  C.  Motor-Generator  Four  Arc  Capacity  ...  18 

Power  Factor  and  Overall  Efficiency  Curves 19 

Electric  Welding  Cycles  (Graphic  Chart) 20 

Specifications  A.  C.  Motor: 

General  Design  and  Technical  Data 21 

Motor-Generator  Set — Construction 22 

Induction  Motor — Stator,  Rotor 22 

Induction  Motor — Rotor,  Ventilation 22-23 

Direct   Current  Generator — Field,  Armature,  Brush  Holder, 

Ventilation 23 

Workmanship  and  Material 23 

Guarantee 24 

Specifications  D.  C.  Motor: 

General  Design  and  Technical  Data 25 

Motor-Generator  Set — Construction 26 

Direct    Current    Generator    and    Motor — Field,    Armature, 

Brush  Holder,  Ventilation 26 

Workmanship  and  Material.    Guarantee 27 

Constant  Current  Control  Panel  for  Welding  and  Cutting — 

General  Description 28 

Constant  Current  Control  Panel  for  Welding  and  Cutting- 
Equipment,  Wiring,  Regulation,  Range  of  Control,  Carbon 

Pile,  Carbon  Pile  Mounting,  Solenoid 29 

Constant  Current  Control  Panel  for  Welding  and  Cutting- 
Solenoid,  Control  Motor,  Limited  Switches 29-30 

Workmanship  and  Material.    Guarantee   ...  30 

Portable  Equipment — -General  Description 31 


62 


SUBJECT  PAGES 

The  Last  Word  in  Electric  Welding ^    .  32 

Specifications  Portable  Welding  Outfit  (Field  Type)    ...        .    .   33-34 
Welding  Metals,  Grade  Sizes  of  Plain  Wire,  Purposes  Used  and 

Tensile  Strength  of  Welds 35 

Complete  Electric  Welding  Equipment  of  the  Wilson  System. 

Patents 36 

Portable  Welding  Outfit  (Field  Type)  (Drawing) 37 

Portable  Welding  Outfit  (Shop  Type)  (Drawing) 38 

Floor  Plan  D.  C.-A.  C.  Motor  (1-2-4  Arc  Capacity) 39 

Floor  Plan  D.  C.-A.  C.  Motor  (6-8  Arc  Capacity) 40 

Results  Obtained  from  use  of  Wilson  System  (Table)     41 

Half-tone  Cuts 42-46 

Reclamation    of  Pneumatic  Hammer  Handle   and   Cutting 

Tools 42 

Boiler  Plate  Welds,  Samples  of  Welded  Cast  Iron  and  Steel 
and  Wrought  Iron,  Reclamation  of  Track  and  Shop  Jacks 

and  Freight  Car  Knuckles 43 

Repairs  to  Walking  Beam  Marine  Engine,  and  Reclamation 

of  Locomotive  Bell 44 

Reclamation  of  Large  Locomotive  Cylinder 45 

Building  up  Flat  Spots  on  Locomotive  Tire.    Four  Operators 

or  Multiple  Panel  Installation 46 

Physical  Tests  of  Electrically  Welded  Joints 47-49 

Economy  and  What  it  Means 50 

A  Lesson  in  Preparedness .....  51 

Useful  Information 52-58 

Weights  and  Measures.    Electrical  Units 52 

Electrical  Units.    Formula  for  Shop  Wiring 52-53 

Examples  of  Wire  Calculations 54 

Wiring  Table 55 

Table  showing  size  of  wire  between  motor-generators  and 
welding  panels,  one  to  eight  in  number,  and  at  distances 
of  one  hundred  feet  to  one  thousand  feet  inclusive,  ex- 
pressed in  circular  mills 56 

Specific  gravity  and  fusing  point  of  metals,   and  weight  per 

cubic  foot  of  various  substances 57 

High   temperatures  judged  by  colors,  various  temperatures 

of  furnaces 58 

How  We  have  been  Received 59 

Blank  Form  for  Entering  Statistical  Data  with  Reference  to  Elec- 
tric WTelded  Flues,  Cost,  Failures,  Engine  Mileage,  Accesso- 
ries, etc 60 

Work  Performed  and  Economies  Effected  Blank 61 

Index  .    62-63 


63 


MEMORANDUM 


J.  C.  &  W.  E.  Powers  Print 
New  York 


UNIVERSITY  OF  CALIFORNIA  LIBRARY, 
BERKELEY 


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